System for monitoring resin flow

ABSTRACT

A system for monitoring of the resin front during resin infusion into a fiber preform for the manufacturing of composites. Such monitoring is based on Optical Frequency Domain Reflectometry by emitting light pulses through optic fibers which forms a resin infusion mesh in a fiber preform.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of the European patent applicationNo. 19382568.4 filed on Jul. 3, 2019, the entire disclosures of whichare incorporated herein by way of reference.

FIELD OF THE INVENTION

The present invention belongs to the field of composites manufacturing,and particularly, it refers to the monitoring of the resin front duringresin infusion into a fiber preform for the manufacturing of composites.

In particular, such monitoring is performed by a system based on OpticalFrequency Domain Reflectometry (‘OFDR’) emitting light pulses throughoptic fibers which forms a resin infusion mesh in the fiber preform toease the fiber infusion.

Therefore, the system of the invention is configured to sense and reportthe in situ resin front through the fiber preform in order to accounteventual actuations in the manufacturing process either in terms ofcycle parameters or modifying resin ports operation.

BACKGROUND OF THE INVENTION

A composite is fiber reinforced polymer formed by two separateconstituents: fibers and resin acting as binding matrix. Thus,manufacturing techniques are conventionally divided according to whetherthese constituents are originally together or separated. In the former,the raw material is called ‘pre-preg’, while on the latter there is, onone hand, dry fabric (so-called fiber preform), and, on the other hand,the resin to be infused/injected therein. Regardless the raw material,once both constituents are finally together, the conjunction issubjected to a curing cycle where pressure, vacuum and/or temperature isapplied over a predetermined time.

A number of techniques are known for the manufacturing of compositeswhen both constituents are originally separated, all addressed under theterm ‘resin infusion manufacturing techniques’. These compositemanufacturing techniques rely on a closed mold hosting the laid-up fiberpreform into which the resin is to be infused/injected. Examples of thisare ‘Resin Film Infusion’ (‘RFI’), ‘Resin Infusion’ (‘RI’), ‘ModifiedVacuum Infusion’ (‘MVI’), or ‘Resin Transfer Molding’ (‘RTM’). Thesespecific techniques differ from each other on the tooling, manufacturingsteps and even curing tools used.

In general terms, the dry fabric or fiber preform is placed into thecavity of a mold, then the mold is closed and the thermoset resin(typically epoxy resin) is injected through a set of injection portsunder relatively low pressure. Once the resin impregnates the wholefiber preform, the conjunction is cured as a finished component to bedemolded from the closed mold in a last step.

Among these steps, special attention should be drawn to the resininjection/infusion since it significantly influences on the quality ofthe finished parts. For instance, resin viscosity, temperature orpressure at the resin port inlets are key parameters for this kind ofmanufacturing process.

Moreover, regarding the fiber preform, the fabric permeability (definedas how easily a fluid can flow through a porous medium) plays anessential role in the infusion process. Although theoreticallypermeability could be measured, in practical applications, issues thatcome up during the preforming (i.e., allocation into the mold) andpreparation stages modify it and make it actually unpredictable so far.

These alterations induced by the preparation tasks in relation to thetheoretical arrangements strongly affect the advance of the resin flowalong the interior of the mold cavity and become a potential source ofdefects such as porosity or lack of impregnation.

Nowadays, a typical approach to solve this problem focusses on thecorrect modelling whose reliability depends on the rightcharacterization of the process and material (that is, the inputs fromthe simulation software) as well as the capability of the worker tohandle the material and carry out the tasks without changing the alreadyestimated simulation inputs.

Non-destructive inspections are performed when the composite parts arefinished as there are aleatory factors contributing to rejection ordiscard of parts, especially due to porosity issues.

As a result, the efforts to improve modelling have only mitigated thesedefects in the finished parts. Hence, in view of the potential defectsin the finished parts which may be rejected, thus entailing a cost andtime-impact, and the solutions found in the state of the art, it isnecessary to provide a cost-effective solution accounting for thecorrect resin flow through the fiber preform in order to increase theproduction rate of finished composites with acceptable quality.

As this solution is of special application in aeronautics, it should becompatible with the processes, quality, and lead time of theaeronautical composite parts such as frames or ribs or any othercomposite part with tight dimensional tolerances.

SUMMARY OF THE INVENTION

The present invention provides a solution for the aforementionedproblems.

In a first inventive aspect, the invention provides a system formonitoring resin flow during resin infusion into a fiber preform for themanufacturing of composites, the system comprising:

an optical reflectometer device configured to emit light pulses throughoptic fibers and to measure the light reflected backwards; and

at least one optic fiber connected to the reflectometer and arranged onor within at least a portion of the fiber preform over a determinedlength,

wherein the at least one optic fiber is distributed so as to form aresin infusion mesh on or within the at least a portion of the fiberpreform; and

wherein the reflectometer is further configured to:

calibrate the timed light pulses with distance based on the determinedlength of the optic fiber arranged on or within the fiber preform;

measure the variation in the light which is reflected backwards for eachlight pulse emitted; and

correlate the distance at which the resin reaches the at least one opticfiber of the resin infusion mesh along its determined length as resinflow advances.

The ‘determined length’ is the distance that a single optic fiber isarranged on (similarly, in contact with) a portion of the fiber preform.There will be as ‘determined lengths’ as times the optic fiber comes inand out of the fiber preform, as it will be explained hereinafterregarding the meandering arrangement of the optic fiber(s).

Light reflected backwards would come from the scattering over the lengthof the fiber optic or from the light reflection from Bragg gratingswritten previously in the optical fiber.

In a particular embodiment, the optical reflectometer device isconfigured to measure backscattering light coming from the scatteringover the length of the fiber optic.

In another particular embodiment, the at least one optic fiber comprisesBragg gratings written therein at least over the determined length andthe optical reflectometer device is configured to measure lightreflected from the Bragg gratings.

In any case, as the optical reflectometer emits light pulses through theoptic fiber(s), these pulses go in and out of the fiber preform as theoptic fiber does. In any of these discontinuities where the optic fiberreaches, for instance, an edge of the fiber preform, light will bereflected backwards returning to the reflectometer.

A reflectometer is a combination of a laser light source and an opticaldetector controlled by electronics and software controls. As thereflectometer emits accurately timed light pulses through the opticfiber, it further observes or measures (by the optical detector) a smallproportion of light that is reflected backwards (so-called backscatter)while the rest keeps propagating forwards traveling along the fiber.Normally, the amount of light backscattered is a small fraction of theemitted pulse, typically less than one millionth.

The amplitude of the reflected light together with the associated timedelay (accounted from the time when the light pulse was emitted) allowsthe identification of distances along the optic fiber (given the speedthe light travels along the optic fiber). To tune-up the reflectometer,it is typically pre-programmed with the value of the Optical Index ofRefraction for the fiber to enable the reflectometer to correctlyidentify the length and position of any discontinuity which are observedas regions of higher or lower (i.e., variations) levels of reflectedlight as the light pulse travels throughout the optic fiber.

In the present invention, the reflectometer should be furthercalibrated—prior to infuse resin in the fiber preform—with thedetermined length(s) of the optic fiber(s) on or within the fiberpreform. In particular, the optical fiber inside the preform should befurther calibrated so that the determined length(s) of the opticfiber(s) are cross correlated with their position in the mold in orderto ease a resin mapping during the infusion. Furthermore, thecoordinates of sections or points of the determined length(s) formingthe resin infusion mesh are calibrated at the beginning of the process,that is, prior to infuse resin.

In other words, the timed light pulses are reflected backwards whenreaching a discontinuity so that timed light pulses can be correlatedwith distance based on the determined length(s).

Therefore, the original features of the reflected light would beassociated to the edges or coordinates of the fiber preform with respectto the mold where the optic fiber(s) comes in or out, in case there beany.

The optic fiber(s) forms a ‘resin infusion mesh’ on or within the fiberpreform or a portion thereof. A resin infusion mesh is a mesh patternwhich promotes resin flow during the infusion process. The resininfusion mesh creates a preferable path for the correct distribution ofthe resin within the fiber preform as it provides a more suitablesurface tension.

Accordingly, in order to form a ‘resin infusion mesh’, the opticfiber(s) may cross each other either in a flat configuration orinterwoven.

Unlike the solutions found in the prior art where the process efficiencyrelies on both the software modelling and operator labor in themanufacturing cycle, the system according to the invention is capable ofsensing the actual location of the resin front by correlating reflectedlight pulse (backscatter or back reflection from fiber Bragg grating,‘FBG’) with the distance at which the resin front reaches (or contact)the optic fiber(s) as this ‘resin front’ creates a discontinuity.Accordingly, the system provides an image of the actual resin frontduring the entire resin infusion process.

The unpredictable factors entailing the rejection of finished parts inthe prior art by the non-destructive tests, are by the present systemavoided since there is a control throughout the whole resin infusionprocess enabling an eventual actuation to offset or compensate for therace tracking. Race track is an undesirable effect which occurs whenthere is an inappropriate resin front speed during infusion or there areareas of the fiber preform with a lack of or insufficient resin.

As a consequence, the present system detects these irregularities in theresin flow such as too low/fast speed or even non-impregnated areas inthe fiber resin. As the resin flow will preferably follow the opticfiber mesh pattern, a correct monitoring of the resin front along theentire predetermined paths(s) of the optic fiber(s) is assured.

Another advantage of the present invention is that the system furtherprovides a direct thermal mapping of the interior of the closed moldduring resin infusion process since the backscattering signal is highlyaffected by temperature. That is, there is still a variation in thebackscattering where the resin reaches the optic fiber but the baselinevalue is different according to the overall temperature inside the mold.

As the resin infusion mesh may cover the entire fiber preform, thetemperature inside the mold may be known through all its extension.

This temperature measurement may be further used to correlate betweenthe actual inner temperature of the mold and the foreseen temperaturefrom modelling to take any necessary action in production.

In a particular embodiment, at least one optic fiber meanders the fiberpreform such that this at least one optic fiber covers the portion ofthe fiber preform over a plurality of determined lengths.

In a particular embodiment, the system further comprises a control unit(controller) configured to receive as inputs:

geometry of the fiber preform,

distribution of the optic fibers on or within the fiber preform formingthe resin infusion mesh at least one determined length, and

from the reflectometer, the resin front as the distance where resin flowreaches the at least one optic fiber along each of the at least onedetermined length;

wherein the control unit is further configured to modify at least oneresin infusion parameter based on the received inputs during themanufacturing process.

That is, the control unit of the system (a controller formed byelectronics and software) automatically acts over at least one infusionparameters on the at least one infusion port of the mold. Normally,these parameters are pressure (related to flow-rate) and temperature(related to viscosity) of the resin to be injected.

In the absence of this control unit, an operator following the resinfront lecture of the present system may likewise manually act over theseparameters. Nevertheless, time delay and accuracy will not be stressed.

In a particular embodiment, the control unit is configured to modify theat least one resin infusion parameter based on a predictive algorithmwhich checks whether a determined estimator is within an establishedconfidence interval.

In a particular embodiment, the control unit is further configured toreceive an expected pathway of resin front determined according to thegeometry of the fiber preform and distribution of the fiber optic, sothat the control unit is configured to modify the resin infusionparameters when the determined estimator is out of the confidenceinterval in such a way that the resin front follows such expectedpathway.

In a second inventive aspect, the invention provides a compositemanufacturing tooling, the tooling comprising:

either a two-part closed mold, or a single-sided mold closed by vacuumbagging;

optionally, caul plates;

heating equipment;

an impregnation driving means; and

a system for monitoring resin flow during resin infusion into a fiberpreform according to any of the embodiments of the first inventiveaspect.

For instance, a two-part closed mold is used in ‘Resin Transfer Molding’(‘RTM’), while a single-sided mold closed by vacuum bagging is used in‘Resin Film Infusion’ (‘RFI’), ‘Resin Infusion’ (‘RI’), or ‘ModifiedVacuum Infusion’ (‘MVI’) manufacturing techniques.

Caul plates can be used with ‘RFI’, ‘RI’, and ‘MVI’ techniques, forinstance.

The heating equipment can be an oven, an autoclave (only suitable for‘RFI’, ‘RI’, and ‘MVI’), an integrally heating infusion equipment for‘MVI’, or even a heated press or integrally heated mold for ‘RTM’.

Furthermore, the impregnation driving means are vacuum (less than 1 bar,absolute pressure) for RFI’, ‘RI’, and ‘MVI’ techniques; while ‘RTM’utilizes pressure (more than 1 bar) and, optionally, ‘RTM’ may be vacuumassisted.

In a third inventive aspect, the invention provides a method formonitoring resin flow during resin infusion into a fiber preform for themanufacturing of composites, the method comprising the following steps:

providing a system for monitoring resin flow according to any of theembodiments of the first inventive aspect; wherein the at least oneoptic fiber is arranged on or within at least a portion of a fiberpreform forming a resin infusion mesh;

emitting by the reflectometer light pulses through the at least oneoptic fiber and measuring light reflected backwards;

calibrating by the reflectometer, the timed light pulses with distancebased on the determined length of the optic fiber arranged on or withinthe fiber preform;

upon resin infusion into the fiber preform, measuring the variation inthat light pulse which is reflected backwards for each light pulseemitted; and

correlating the distance at which the resin reaches the at least oneoptic fiber of the resin infusion mesh along its determined length asresin flow advances.

In a fourth inventive aspect, the invention provides a method formanufacturing a composite, the method comprising the steps of:

providing a composite manufacturing tooling according to any of theembodiments of the second inventive aspect;

laying up at least one fiber preform onto the mold;

arranging the at least one optic fiber on a portion of the fiber preformforming a resin infusion mesh;

closing the mold by either a closing mold, or by vacuum bag;

applying heat by the heating equipment;

applying vacuum and/or pressure by the impregnation driving means;

injecting or infusing the resin into the fiber preform; and

monitoring the resin flow during the resin infusion into a fiber preformaccording to any of the embodiments of the method according to the thirdinventive aspect.

It is to be noted that the optic fiber(s) is arranged on a portion ofthe fiber preform forming a resin infusion mesh. If there are more thanone layer of the fiber preform, the optic fiber(s) may be arranged onany intermediate step of the laying-up or stacking process so that atleast one optic fiber is left embedded therein.

All the features described in this specification (including the claims,description and drawings) and/or all the steps of the described methodcan be combined in any combination, with the exception of combinationsof such mutually exclusive features and/or steps.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other characteristics and advantages of the invention willbecome clearly understood in view of the detailed description of theinvention which becomes apparent from a preferred embodiment of theinvention, given just as an example and not being limited thereto, withreference to the drawings.

FIG. 1 shows a schematic arrangement of an optic fiber on or within atleast a portion of a fiber preform.

FIG. 2a shows a particular embodiment of the variation measure in thereflected light for a light pulse emitted during the calibration stepvs. the length of the optic fiber shown in FIG. 1.

FIG. 2b shows a particular embodiment of the variation measure in thereflected light for each light pulse emitted vs. the length of the opticfiber shown in FIG. 1.

FIG. 3 shows different pictures at different times recorded by a videocamera with the progression of the resin front through the fiber preformshown in FIG. 1.

FIG. 4 shows the results for each determined length of the optic fibershown in FIG. 2, as well as results from the video camera plottedseparately vs. time.

FIG. 5 shows a plot of Darcy's Law with the advance of the resin frontvs. the optic fiber length for a portion thereof.

FIG. 6 shows a schematic illustration of an optic fiber within a fiberpreform in a mold of the system of an embodiment of the presentinvention having a single-sided mold enclosed by a heater and vacuumbagging.

FIG. 7 shows a schematic illustration of a side view of a two-partclosed mold, with caul plates, in an embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As it will be appreciated by one skilled in the art, aspects of thepresent description may be embodied as a system (10), a compositemanufacturing tooling (11) or a method.

As it was mentioned, the present invention provides a system (10)capable to identify anomalies in the resin front (2) and, as aconsequence, the global production system—by the interfaces betweenproduction controls and this monitoring system (10)—may modify in situthe injection parameters to correct, offset or compensate the potentialdefects (such as porosity) in the finished parts.

FIG. 1 depicts an example of schematic arrangement of an optic fiber (1)on or within at least a portion of a fiber preform (3). For illustrativepurposes, only one optic fiber (1) is shown.

The fiber preform (3) schematically shown in top view are five compositefabric layers (unidirectional fabric layers) with dimensions of 250×290mm. Furthermore, the optic fiber (1) meanders such fiber preform (3)such that the at least one optic fiber covers the portion of the fiberpreform over three determined lengths, named as (A), (B), and (C).

These determined lengths (A, B, C) or segments of the optic fiber comingin and out the fiber preform cover:

Determined length (A) from 0.7413 to 0.942 m. of the fiber optic (1),

Determined length (B) from 1.4304-1.231 m. of the fiber optic (1), and

Determined length (C) from 1.8327 to 2.050 m. of the fiber optic (1).

For infusing the resin into the fiber preform (3) for the compositemanufacturing, the composite manufacturing tooling (11) comprises asingle-sided aluminum mold (plate) (12) closed by vacuum bagging (13).The vacuum bagging (13) allows seeing through, so a video camera (14)may record the resin front (2) throughout the resin infusion process aswill be explained in FIG. 3 for comparative purposes.

FIGS. 2a and 2b depict the actual variation in the reflected lightmeasured for each light pulse emitted by the reflectometer (18) vs. thelength of the optic fiber detailed in FIG. 1. Particularly in thesefigures, the backscattered light measured by the optical reflectometerdevice (18) is depicted. Light reflected backwards may come from thescattering over the length of the fiber optic or from the lightreflection from Bragg gratings (28) written previously in the opticalfiber (1).

The backscattering of the optic fiber vs. distance before injectionenables the calibration of the timed light pulses with distance based onthe three determined lengths (A, B, C) of the optic fiber (1) arrangedwith the fiber preform. That is, without resin infused yet, thebackscatter peaks (16) shown in the graph of FIG. 2a correspond to theedges (3.1) of the fiber preform (3) where the meandering optic fiber(1) comes in or out. In another particular embodiment, the at least oneoptic fiber (1) comprises Bragg gratings (28) written therein at leastover the determined length and the optical reflectometer device (18) isconfigured to measure light reflected from the Bragg gratings.

Comparison between the initial situation (FIG. 2a ) and over the time(FIG. 2b ) provides the precise location of the resin flow front (2).

FIG. 2b shows the amplitude of the intensity in reflected light signalfor the different fiber determined lengths. As it may be seen, the threedetermined lengths of FIG. 1 (identified as (A), (B) and (C)) correspondto each of the ‘wells’ in FIG. 2 b.

Upon injection/infusion starts, as the resin front (2) advances, itgradually reaches the optic fiber (1)—of the resin infusion mesh—alongits determined lengths (A, B, C), the optical backscattering of theoptic fiber is progressively modified and the measurement of thebackscattering variation allows the following of the evolution of theresin flow front (2) inside the mold.

The evolution of the optical backscattering response over the injectiontime can be seen separately for each determined length (A), (B) and (C).Therefore, for this example where uniform resin front (2) is expected,if resin position in each determined length is seen unbalanced, it mayentail race tracking.

The measurements of FIG. 2b show a baseline (15) from which respectivepeaks (16) project. These peaks (16) may be associated to edges (3.1) ofthe fiber preform (3) or ends of the determined distances in FIG. 2a ,as well as the resin front (2) in FIG. 2b . As it can be seen, theevolution of the optical backscattering response is a displacement ofthe peaks (16) shown in FIG. 2b , while the baseline (15) is anindicator of the temperature inside the mold.

The coincidence or intersecting points between the baseline (15) and thepeaks (16) once the injection has begun inside the mold determines thesubsequent positions of the resin front (2). Therefore, by detecting theintersecting points of all the peaks (16) of each of the graphs with thebaseline (15), the resin front (2) advancement is monitored. This resinfront (2) evolution (inferred by the peaks (16)) is represented in FIG.2 b.

As the resin front (2) advances, these peaks (16) may distort and becomedifficult to identify the exact point where the resin front locates asthe peaks (16) are less abrupt or do not distinguishably intersect thebaseline (15). A relation between intersection point with the baseline(15) and inclination of the peak (16) will be described in the followingfor the correct identification of the resin front.

The resin flow front flow (2) has been monitored not only by variationof the optic fiber (1) backscattering, but also by a video camera (14)for correlating the results. FIG. 3 shows a set of instant pictures atdifferent times recorded by the video camera (14) with the progressionof the resin front (2) through the fiber preform (3).

The dark area corresponds to the portion of the fiber preform (3) whereresin has impregnated, while the lighter area is still dry fabric. Itcan be further seen that there is a uniform resin front (2), so no racetracking has taken place.

In FIG. 4, the measurements of both technologies (the reference videocamera, and the system (10) according to the invention) have beenplotted together. It is shown that the backscattering measurements fromoptic fiber (1) reproduces the logarithmic expression that usuallydefines resin advancement (2). Results for each determined length of theoptic fiber shown in FIG. 2 have been plotted separately.

The light pulses emitted by the reflectometer (18) and video camerarecording have been time synchronized and switch-on simultaneously.Thus, the reliability of the distributed fiber data is demonstrated. Inparticular, the reference position of determined length B has been takenfor the video camera recording in the present experiment, in otherwords, it has been taken how resin front advances along the middle pointof the fiber preform.

As it was mentioned, the system (10) of the present invention mayfurther comprise a control unit (20) configured to receive inputs aboutthe fiber preform geometry and optic fiber(s) distribution as well asthe resin front from the reflectometer (18). Based on these receivedinputs, the control unit (20) modifies at least one resin infusionparameter during the manufacturing process.

The control unit (20) functioning is based on a predictive algorithmchecking whether a determined estimator calculated by the results ofFIG. 2b is within an established confidence interval.

This predictive algorithm utilizes a multiple regression model andcalculation by least squares of the estimators. The estimators are theslope of the peaks (16) and the intersection with the baseline (15), andare calculated by matrix operations.

Therefore, these points that identify the resin front position for eachlight pulse emitted by the reflectometer (18) are expected to be withina confidence interval established in the predictive model. If so, i.e.,if the next measurement corresponding to the next light pulse emitted bythe reflectometer (18), particularly the point intersecting the baselinefor each determined length of the optic fiber, is within the confidenceinterval (i.e., with α=0.05), the same adjustment is used for nextpoint. However, if the next detected point is not within the confidenceinterval, two possible options may be followed:

-   -   i. either modifying the infusion parameters from the ports so        that the resin front follows the adjustment of the previous        behavior; or    -   ii. selecting this point as the new valid point and then        estimating the following point according to the new curves that        include this point.

For N observations (where the ‘observations’ are the group of points foreach of the curves of FIG. 2b , that is, each light pulse), theregression straight line has n+1 estimating parameters as follows:y=X·β+u

Where ‘y’ is the response vector, ‘X’ the matrix of experimentalvariables, ‘β’ the parameter vector containing each of the estimatorsbelonging to each of the variables or the observations, and ‘u’ is anerror vector associated with the adjustment.

In addition, the vector of estimator parameters is as follows{circumflex over (β)}=(X ^(T) X)⁻¹ X ^(T) ·y

If the adjustment is given, the response vector (‘y’) for ‘X’observations is estimated as follows:ŷ=X·{circumflex over (β)}

Wherein symbol ‘{circumflex over ( )}’ denotes ‘estimated’. Moreover, byhaving a point (x, y), the deviation from the value predicted by ourlinear regression adjustment can be determined.

This deviation or distance being defined as:e=y−ŷ

Wherein ‘y’ is the experimental value and ‘ŷ’ is the estimated value.

By analyzing the variance with the new estimated point, and furtherusing the statistical hypothesis set by p-value, the significance of themodel may be determined within a determined level of significance alpha(particularly, α=0.05). This calculation not only validates the modelbut also corroborates the high correlation of the variables thatparticipate in the inference process (x_(i), y_(i)).

On the other hand, by calculating the confidence interval of a newestimated point with the former significant model, it can be determinedwhich points are to be within that confidence interval and thus, in casethe point of intersection is not clear for instance due to signalsmearing, estimating it within the confidence interval.

This prediction assist in knowing which parameters need to be controlled(speed, pressure, temperature, etc.) in case the new experimental pointwithin the predictor model is not known.

All these estimations are repeated for each of the experimental pointsdetected allowing those fuzzy (due to the experimental deficienciesdiscussed above) to be further studied. Therefore, the advancement ofthe resin front (2) is accurately defined and reducing the error in thepoints of intersection with the baseline (15).

The advance of the resin front by the points of intersection in thefirst determined length (A) of FIG. 2b is represented by the curve shownin FIG. 5. It corresponds to a potential adjustment or Darcy's Lawaccounting the advance of the resin front.

As from the intersecting points shown in FIG. 5, the advance of thefluid front may be estimated in case such points of intersection are nottotally clear. In this scenario, for the adjustment, a non-linearstatistical inference (Xn type, with n approximately 0.5 if the advanceis deemed correct) may be performed.

It should be noted that the final part of the resin front is where thefuzziest points may be seen, and therefore the adjustment needed,particularly for the final 20% of the resin front through the fiberpreform. In that portion, new points and their errors should beestimated deciding whether to act in order to correct the resin frontadvance. Similarly, in the event that none of the curves intersect, theprevious optimization method may be used to determine the properintersection and therefore calculate the point of the advance of theresin front in that area of the fiber preform.

It is furthermore noted that a high correlation in how the resin frontadvances along the different determined lengths of the optic fiber (1)entails a more homogeneous resin front.

In a second inventive aspect, the invention provides a compositemanufacturing tooling (11), the tooling comprising either a two-partclosed mold (30)(FIG. 7), or a single-sided mold (12) (FIG. 6) closed byvacuum bagging (13); optionally, caul plates (32); heating equipment(24); an impregnation driving means (26); and a system (10) formonitoring resin flow during resin infusion into a fiber preformaccording to any of the embodiments of the first inventive aspect.

While at least one exemplary embodiment of the present invention(s) isdisclosed herein, it should be understood that modifications,substitutions and alternatives may be apparent to one of ordinary skillin the art and can be made without departing from the scope of thisdisclosure. This disclosure is intended to cover any adaptations orvariations of the exemplary embodiment(s). In addition, in thisdisclosure, the terms “comprise” or “comprising” do not exclude otherelements or steps, the terms “a” or “one” do not exclude a pluralnumber, and the term “or” means either or both. Furthermore,characteristics or steps which have been described may also be used incombination with other characteristics or steps and in any order unlessthe disclosure or context suggests otherwise. This disclosure herebyincorporates by reference the complete disclosure of any patent orapplication from which it claims benefit or priority.

The invention claimed is:
 1. A system for monitoring resin flow duringresin infusion into a fiber preform for manufacturing of composites, thesystem comprising: an optical reflectometer device configured to emittimed light pulses through optic fibers and to measure light reflectedbackwards; and at least one optic fiber connected to the reflectometerand arranged on or within at least a portion of the fiber preform over adetermined length, wherein the at least one optic fiber is distributedso as to form a resin infusion mesh on or within the at least a portionof the fiber preform; and wherein the reflectometer is furtherconfigured to: calibrate the timed light pulses with distance based onthe determined length of the optic fiber arranged on or within the fiberpreform; measure a variation in the light which is reflected backwardsfor each light pulse emitted; and correlate a distance at which theresin reaches the at least one optic fiber of the resin infusion meshalong its determined length as resin flow advances.
 2. The systemaccording to claim 1, wherein the optical reflectometer device isconfigured to measure backscattering light.
 3. The system according toclaim 1, wherein the at least one optic fiber comprises Bragg gratingswritten therein at least over the determined length, and the opticalreflectometer device is configured to measure light reflected from theBragg gratings.
 4. The system according to claim 1, wherein at least oneoptic fiber meanders the fiber preform such that said at least one opticfiber covers the portion of the fiber preform over a plurality ofdetermined lengths.
 5. The system according to claim 1, wherein thesystem further comprises a controller configured to receive as inputs: ageometry of the fiber preform, distribution of the optic fibers on orwithin the fiber preform forming the resin infusion mesh at least onedetermined length, and from the reflectometer, the resin front as thedistance where resin flow reaches the at least one optic fiber alongeach of the at least one determined length; wherein the controller isfurther configured to modify at least one resin infusion parameter basedon the received inputs during a manufacturing process.
 6. The systemaccording to claim 5, wherein the controller is configured to modify theat least one resin infusion parameter based on a predictive algorithmwhich checks whether a determined estimator is within an establishedconfidence interval.
 7. The system according to claim 6, wherein thecontroller is further configured to receive an expected pathway of theresin front determined according to the geometry of the fiber preformand distribution of the fiber optic, so that the controller isconfigured to modify the resin infusion parameters when the determinedestimator is out of the confidence interval such that the resin frontfollows such expected pathway.
 8. A composite manufacturing tooling, thetooling comprising: either a two-part closed mold, or a single-sidedmold closed by vacuum bagging; heating equipment; an impregnationdriving means; and a system for monitoring resin flow during resininfusion into a fiber preform according to claim
 1. 9. The compositemanufacturing tooling according to claim 8, the tooling furthercomprising caul plates.
 10. A method for monitoring resin flow duringresin infusion into a fiber preform for manufacturing of composites, themethod comprising the following steps: providing a system for monitoringresin flow according to claim 1; wherein the at least one optic fiber isarranged on or within at least a portion of a fiber preform forming aresin infusion mesh; emitting by the reflectometer light pulses throughthe at least one optic fiber and measuring light reflected backwards;calibrating by the reflectometer, the timed light pulses with distancebased on the determined length of the optic fiber arranged on or withinthe fiber preform; upon resin infusion into the fiber preform, measuringthe variation in that light pulse which is reflected backwards for eachlight pulse emitted; and correlating the distance at which the resinreaches the at least one optic fiber of the resin infusion mesh alongits determined length as resin flow advances.
 11. The method accordingto claim 10, wherein the system further comprises a controllerconfigured to receive as inputs: a geometry of the fiber preform,distribution of the optic fibers on or within the fiber preform formingthe resin infusion mesh at least one determined length, and from thereflectometer, the resin front as the distance where resin flow reachesthe at least one optic fiber along each of the at least one determinedlength; wherein the controller is further configured to modify at leastone resin infusion parameter based on the received inputs during themanufacturing process, the method further comprising the step of:modifying at least one resin infusion parameter based on the receivedinputs during the manufacturing process.
 12. The method according toclaim 11, wherein the controller is configured to modify the at leastone resin infusion parameter based on a predictive algorithm whichchecks whether a determined estimator is within an establishedconfidence interval, the method further comprising the steps of:checking, by the controller, whether a determined estimator is within anestablished confidence interval set by a predictive algorithm; andmodifying the at least one resin infusion parameter accordingly.
 13. Themethod according to claim 12, wherein the controller is furtherconfigured to receive an expected pathway of the resin front determinedaccording to the geometry of the fiber preform and distribution of thefiber optic, so that the controller is configured to modify the resininfusion parameters when the determined estimator is out of theconfidence interval such that the resin front follows such expectedpathway, the method further comprising the step of: modifying, by thecontroller, at least one resin infusion parameter when the determinedestimator is out of the confidence interval in such a way that the resinfront follows the expected pathway.
 14. A method for manufacturing acomposite, the method comprising the steps of: providing a compositemanufacturing tooling according to claim 8; laying up at least one fiberpreform onto the mold; arranging the at least one optic fiber on orwithin at least a portion of said fiber preform forming a resin infusionmesh; closing the mold by either a closing mold, or by vacuum bag;applying heat by the heating equipment; applying at least one of vacuumand pressure by the impregnation driving means; injecting or infuse theresin into the fiber preform; monitoring the resin flow during the resininfusion into a fiber preform by: emitting by the reflectometer lightpulses through the at least one optic fiber and measuring lightreflected backwards; calibrating by the reflectometer, the timed lightpulses with distance based on the determined length of the optic fiberarranged on or within the fiber preform; upon resin infusion into thefiber preform, measuring the variation in that light pulse which isreflected backwards for each light pulse emitted; and correlating thedistance at which the resin reaches the at least one optic fiber of theresin infusion mesh along its determined length as resin flow advances.